2004 SUBARU FORESTER belt

ME(H4SO)-62
MECHANICAL
Cylinder Head
20.Cylinder Head
A: REMOVAL
1) Remove the V-belt. MOVAL, V-belt.>
2) Remove the crank pulley. 45, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. ME(H4SO)-47, REMOVAL, Timing Belt Cover.>
4) Remove the timing belt. REMOVAL, Timing Belt.>
5) Remove the cam sprocket. 53, REMOVAL, Cam Sprocket.>
6) Remove the intake manifold. 14, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs A/C compressor
bracket on cylinder head.
8) Remove the valve rocker assembly. ME(H4SO)-56, REMOVAL, Valve Rocker Assem-
bly.>
9) Remove the camshaft. REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
NOTE:
Leave the bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.
11) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
12) Remove the bolts (a) and (c) to remove cylinder
head.
13) Remove the cylinder head gasket.CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
14) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
 Use new cylinder head gaskets.
 Be careful not to scratch the mating surface
of cylinder block and cylinder head.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
(3) Back off all bolts by 180° in reverse order of
installation, and back them off again by 180°.
(4) Tighten all bolts to 42 N⋅m (3.9 kgf-m, 31 ft-
lb) in alphabetical sequence.
(5) Tighten all bolts by 80° — 90° in alphabeti-
cal sequence.
(6) Tighten all bolts by 40° — 45° in alphabeti-
cal sequence.
NOTE:
Do not tighten the bolts more than 45°.
(7) Further tighten bolts (a) and (b) by 40° —
45°.
NOTE:
Ensure the total “re-tightening angle” in the [former
two steps], do not exceed 90°.
3) Install the camshaft. STALLATION, Camshaft.>
4) Install the valve rocker assembly. ME(H4SO)-56, INSTALLATION, Valve Rocker As-
sembly.>
5) Install the A/C compressor bracket on cylinder
head.
6) Install the intake manifold. 16, INSTALLATION, Intake Manifold.>
ME-00278
(c)
(b)
(f)
(d) (a)(e)
ME-00278
(c)
(b)
(f)
(d) (a)(e)
ME-00279
(c)
(b)(f)
(d) (a)
(e)

ME(H4SO)-63
MECHANICAL
Cylinder Head
7) Install the cam sprocket. INSTALLATION, Cam Sprocket.>
8) Install the timing belt assembly. ME(H4SO)-49, INSTALLATION, Timing Belt.>
9) Install the timing belt cover. 47, INSTALLATION, Timing Belt Cover.>
10) Install the crank pulley. INSTALLATION, Crank Pulley.>
11) Install the V-belt. STALLATION, V-belt.>C: DISASSEMBLY
1) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring, and then remove the valve spring retainer
key. Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
 Mark each valve to prevent confusion.
 Use extreme care not to damage the lips of in-
take valve oil seals and exhaust valve oil seals.
ME-00280
ST

ME(H4SO)-69
MECHANICAL
Cylinder Block
21.Cylinder Block
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely.
1) Remove the intake manifold. 14, REMOVAL, Intake Manifold.>
2) Remove the V-belt. MOVAL, V-belt.>
3) Remove the crank pulley. 45, REMOVAL, Crank Pulley.>
4) Remove the timing belt cover. ME(H4SO)-47, REMOVAL, Timing Belt Cover.>
5) Remove the timing belt. REMOVAL, Timing Belt.>
6) Remove the cam sprocket. 53, REMOVAL, Cam Sprocket.>
7) Remove the crank sprocket. 45, REMOVAL, Crank Pulley.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the rocker cover.
10) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
NOTE:
Leave bolts (a) and (c) engaged by three or four
threads to prevent cylinder head from falling.
11) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.12) Remove the bolts (a) and (c) to remove cylinder
head.
13) Remove the cylinder head gasket.
NOTE:
Do not scratch the mating surface of cylinder head
and cylinder block.
14) Similarly, remove the right side cylinder head.
15) Remove the clutch housing cover. (MT model)
16) Remove the flywheel (MT model) or drive plate
(AT model).
Using the ST, lock the crankshaft.
ST 498497100 CRANKSHAFT STOPPER
 MT model
 AT model
(A) Front
ME-00296
(a)
(b)(c) (e)
(f) (A)
(d)
(A) Front
ME-00296
(a)
(b)(c) (e)
(f) (A)
(d)
NE-00297ST
ME-00298

ME(H4SO)-81
MECHANICAL
Cylinder Block
 Model with ATF warmer
28) Install the water by-pass pipe for heater.
29) Get a engine oil filter and apply a thin coat of
engine oil to the seal rubber.
30) Install the oil filter by turning it by hand, being
careful not to damage the seal rubber.
 Tighten the oil filter 80 mm (3.15 in) or 65 mm
(2.56 in) in diameter by approx. 2/3 — 3/4 rotation
more after the seal rubber of oil filter comes in con-
tact with cylinder block or oil cooler.
 Tighten the oil filter 68 mm (2.68 in) in diameter
by approx. 1 rotation more after the seal rubber of
oil filter comes in contact with cylinder block or oil
cooler.
CAUTION:
Do not tighten excessively, or oil may leak.
31) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N⋅m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N⋅m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
(3) Back off all bolts by 180° in reverse order of
installation, and back them off again by 180°.
(4) Tighten all bolts to 42 N⋅m (3.9 kgf-m, 31 ft-
lb) in alphabetical sequence.
(5) Tighten all bolts by 80° — 90° in alphabeti-
cal sequence.
(6) Tighten all bolts by 40° — 45° in alphabeti-
cal sequence.
NOTE:
Do not tighten the bolts more than 45°.
(7) Further tighten bolts (a) and (b) by 40° —
45°.NOTE:
Ensure the total “re-tightening angle” in the [former
two steps], do not exceed 90°.
32) Install the oil level gauge guide and tighten the
attaching bolt (left side only).
33) Install the rocker cover.
34) Install the crank sprocket. 55, INSTALLATION, Crank Sprocket.>
35) Install the cam sprocket. 53, INSTALLATION, Cam Sprocket.>
36) Install the timing belt assembly. ME(H4SO)-49, INSTALLATION, Timing Belt.>
37) Install the belt cover. INSTALLATION, Timing Belt Cover.>
38) Install the crank pulley. INSTALLATION, Crank Pulley.>
39) Install the generator and A/C compressor
brackets on cylinder head.
40) Install the V-belt. STALLATION, V-belt.>
41) Install the intake manifold. 16, INSTALLATION, Intake Manifold.>
ME-02017
(B) (C) (D)(E)(F)
(A)
ME-00279
(c)
(b)(f)
(d) (a)
(e)

ME(H4SO)-91
MECHANICAL
Engine Trouble in General
22.Engine Trouble in General
A: INSPECTION
NOTE:
“RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK
1. Engine will not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
Defective starter B
Battery Poor terminal connection A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
Seized or stuck piston and cylinder C
2) Initial combustion does
not occur. Starter Defective starter C
Engine control system A
Fuel line Defective fuel pump and relay A
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
3) Initial combustion occurs. Engine control system A
Intake system Defective intake manifold gasket B
Defective throttle body gasket B
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B

ME(H4SO)-92
MECHANICAL
Engine Trouble in General
4) Engine stalls after initial
combustion. Engine control system A
Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
Defective intake manifold gasket B
Defective throttle body gasket B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timing B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B
2. Rough idle and engine
stallEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve C
Loosened oil filler cap B
Dirty air cleaner element C
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective timing C
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Defective rocker cover gasket C
Cooling system Overheating C
Others Malfunction of evaporative emission control system A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4SO)-93
MECHANICAL
Engine Trouble in General
3. Low output, hesitation and
poor accelerationEngine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose B
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element A
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
Improper valve seating B
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Cooling system Overheating C
Over cooling C
Others Malfunction of evaporative emission control system A
4. Surging Engine control system A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold gasket B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element B
Fuel line Defective fuel pump and relay B
Clogged fuel line B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Cooling system Overheating B
Others Malfunction of evaporative emission control system C TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK

ME(H4SO)-94
MECHANICAL
Engine Trouble in General
5. Engine does not return to
idle.Engine control system A
Intake system Loosened or cracked vacuum hose A
Others Stuck or damaged throttle valve A
Accelerator cable out of adjustment B
6. Dieseling (Run-on) Engine control system A
Cooling system Overheating B
Others Malfunction of evaporative emission control system B
7. After burning in exhaust
systemEngine control system A
Intake system Loosened or cracked intake duct C
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose B
Defective PCV valve B
Loosened oil filler cap C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Malfunction of evaporative emission control system C
8. Knocking Engine control system A
Intake system Loosened oil filler cap B
Belt Defective timing B
Compression Incorrect valve clearance C
Incorrect valve timing B
Cooling system Overheating A
9. Excessive engine oil con-
sumptionIntake system Loosened or cracked PCV hose A
Defective PCV valve B
Loosened oil filler cap C
Compression Defective valve stem A
Worn or stuck piston rings, cylinder and piston A
Lubrication system Loosened oil pump attaching bolts and defective gas-
ketB
Defective oil filter seal B
Defective crankshaft oil seal B
Defective rocker cover gasket B
Loosened oil drain plug or defective gasket B
Loosened oil pan fitting bolts or defective oil pan B TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK